Electrical box, integrated flange and cover mechanisms

ABSTRACT

A “no profile” electrical box, integrated flange/protective assembly and interchangeable cover that obscures standard electrical outlets such that a wall surface appears nearly continuous, uninterrupted by the outlet or cover when in use or not in use. The profile of the combined unit equals only the thickness of the material from which it is constructed; no hinges, screws or fasteners of any kind are visible and no part of the assembly requires detachment or storage when the outlet is in use, as the hinged cover is undetectably stored in the electrical box, or may be used to cover the electrical cords when engaged in the outlet. Exemplary embodiments of the cover obscure the electrical outlet. Together, the electrical box and flange assembly allow the electrical outlet to be flush mounted or recessed interchangeably, even after installation.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to mechanisms for mounting electricaloutlets.

2. Description of the Related Art

Techniques for mounting and covering standard electrical outlets areinnumerable. Most variations concern one of three themes, (i) safety forsmall children, (ii) aesthetics or (iii) recession for electrical cordmanagement. Despite the abundance of related art in this sector,practically all indoor electrical outlet boxes and covers sold in theUnited States are of traditional design, with little of the patentedderivatives finding any level of commercial appeal. The failure ofcurrent designs to penetrate the commercial market results from thefollowing:

-   -   i) In terms of safety: obtrusive aesthetic design, excessive        manufacturing cost or difficulty in installation. Electrical        outlet installation is generally permanent in nature, while        children's safety is required only periodically and temporarily.        Safety features impede normal access to outlets in such a manner        as to deter the housing developers from incorporating permanent        inconveniences to a majority of customers on behalf of a        minority of customers. Also, the construction necessary to        retrofit an outlet for this temporary purpose is cost        prohibitive and impractical. Therefore add-on temporary products        such as plastic electrical outlet safety caps dominate the        marketplace.    -   ii) In terms of aesthetics, most designs, (a) amount to a        derivative of a cap that protrudes from the wall, clearly        visible and therefore creating limited appreciable aesthetic        benefit, (b) incorporate covers that either require storage        elsewhere when the outlet is in use or that are more obtrusive        when the outlets are in use than cover-free outlets, (c) require        excessive manufacturing cost, (d) require additional labor for        the home and office contractors.    -   iii) In terms of recessed outlet design, (a) too many electrical        devices utilize low voltage transformers or other plugs that a        recessed outlet will not accommodate, thereby preventing        prevalent installation, (b) a recessed design that fails to        incorporate aesthetic closures and easy closing mechanisms        offers limited benefit outside of special applications. As a        result, installations of such designs are relegated to specialty        uses such as wall-mounted audio visual equipment.

Home builders recognize the aesthetic detraction of standard outlets, asevidenced by the increasing practice of obscuring kitchen outletsthrough under-cabinet mounting, despite more difficult access forconsumers. Such mounting preserves the clean, uninterrupted visualappearance of a kitchen wall. However, no other room in a home or officebuilding offers such a means of obscuring the electrical outlets in amanner that would preserve the aesthetics of an un-breached wall. Thelack of commercial penetration by electrical boxes other than ofstandard design is evidence that no current design has incorporated thefour necessary elements:

-   -   (i) aesthetically appealing design,    -   (ii) user-friendly mechanical operation that provides easy        access to the outlet,    -   (iii) competitive manufacturing cost, and/or    -   (iv) the same field installation steps as used for standard        boxes and covers.

In terms of aesthetic improvement referenced in (i) above, the outlet,when not in use should closely resemble the surrounding wall. Featuresthat can improve the aesthetic appearance so include (a) minimal profilesuch that difference in depth is difficult to perceive, (b) no exposedscrews or hinges, (c) limited gaps around the cover closure and (d)paintable material to be painted the same color as the drywall.

Proper mechanical operation referenced in (ii) above, requires that theoutlet not be particularly more difficult to access than are standardexposed outlets, can be accessed with one hand while holding anelectrical plug and/or must not require the removal and storage of adetachable cover.

As referenced in (iii) above, the parts used for mechanical operationand the general design as a whole cannot be significantly more expensiveto manufacture than standard boxes and cover plates.

Installation of the box, flange and cover in new construction must beconsistent with current practice as referenced in (iv) above, requiringno additional labor, time, or skills to install.

A design that sufficiently incorporates any of the individual elementswould be unique. A design that incorporates all elements in combinationwould be additionally unique. However, no prior art has produced designsof any one of these elements sufficient to penetrate the currentmarketplace with these individual attributes and particularly incombination with one another.

SUMMARY OF THE INVENTION

The present invention is a multi-configured electrical box, integratedflange and various cover mechanisms. Each feature of themulti-configured electrical box, flange and cover represent a separateembodiment and each design can be independent of, and freely combinablewith, the others. An object of the present invention is to obscureelectrical outlets in new construction and remodeling such that when notin use, they are generally indistinguishable from the surrounding walland when in use are no more, or are less prominent than standarduncovered outlets. Also, by obscuring and covering outlets, theinvention provides a level of safety for children and provides energysavings. Although the information herein, including the DetailedDescription, concerns the concealment of electrical outlets, the presentinvention could be readily adapted to cover any type of outlet includinga phone jack, cable outlet, or other outlet as understood by one ofordinary skill in the art. Furthermore, while such electrical outletsare generally described as adjoined by a drywall surface, the inventionis not so limited and may be installed, for example, on floors, ceilingsand at other desirable locations having a variety of surface materials.

The electrical box integrates and incorporates various cover mechanismssuch that covers are unseen when the outlet is in use and certainmechanisms obscure the connection between the electrical plugs andoutlets when outlets are in use. One embodiment of the box is configuredto allow the electrical outlet to be mounted in a recessed andun-recessed position interchangeably before and after original outletinstallation. The box is vertically reversible and therefore capable ofmounting on either side of a 2×4 frame. The technique for installing thebox, cover and flange are virtually identical to those required forstandard outlets.

The integrated design of the electrical box, flange and cover obscurethe outlet when not in use. Other embodiments can obscure one outletwhen the other is in use, can obscure both outlets when in use, and/orcan be recessed inside the electrical box, undetectable when the outletis in use.

Different embodiments incorporate various closure mechanisms, including:spring loaded counterweight, gravity, flat magnet, spring-loaded magnet,detent, or track mounted sectional doors, each closure mechanismaccommodating the low-profile design of the cover and flange and isundetectable when the outlet is in use.

In the below embodiments of the present invention, the integrated flangecovers the drywall cutout for the electrical box, protects from exposedwires in the outlet, seals the gap between electrical box and drywallfrom which energy is lost, and aligns with the cover when the cover isclosed. In further embodiments, an interior compartment or wall furtherprotects from exposed wires in the outlet. The configuration andfastening mechanism allows no screws or hinges to be exposed and for theflange to protrude from the wall by only the width of the material fromwhich it is constructed. The alignment with the closed cover and the lowprofile design provide the illusion of no-profile cover flush with thewall.

The invention overcomes limitations of related art as follows:

-   -   1. Aesthetics: The protrusion of covered outlets when viewed        from the front and particularly from the side has significant        affect on perceived aesthetics. Second to color, depth of an        object compared with its immediate surroundings most heavily        influences its relative prominence. Depth is a perceptual        process function involving three-dimensional organization of        stimuli. Contributors to the perception of objects include        shadows, which indicate distance, linear perspective, the        convergence of parallel tracks or lines as they recede into the        distance and among others, retinal disparity—the differences        among images on the retinas of the two eyes. In order to        accommodate the effect that depth perception has on the        prominence or obscurity of an object, the design of the invented        item incorporates the lowest profile possible and alignment of        all components via the relationship between the door, flange and        wall. For example, specific embodiments may achieve a profile of        1 mm—2 mm (depending on the material used); however, the        invention is not limited to such a range. This depth to the wall        averages approximately 900% less than that of related art. This        is accomplished by the integrated design of box, flange and        cover as more thoroughly described under Detailed Description.

Unlike prior art, the invention does not include exposed screws or otherfasteners, hinges, or the profile associated with these mechanisms.

When the outlet is in use, the cover remains attached to the unit.Through the hinge system of the box, the cover opens to one side andinside the box, obscured from view. This differs from prior art that,when the outlet is in use, includes (i) plates that slide over the wall,substantially increasing the prominence of the unit by increasing thearea covered by the outlet and its components, (ii) hinge systems thatprotrude out from the wall, causing the cover to rest partly over theelectrical plugs and therefore more prominent than are uncovered outletswhen engaged and (iii) removable covers that require storage.

-   -   2. Ease of access: Related art uses covers that impede access,        removable covers and other mechanisms that require two hands or        two steps in order to engage an electrical device with an        outlet. The lack of market penetration by related art partly        reflects that the marketplace will not sacrifice functionality        for aesthetics, in addition to limited aesthetic benefits having        been introduced. The cover of the invented item can be opened        with one hand while holding the electrical cord. Once opened,        the cover does not interfere with the effort to engage the        electrical cord in the outlet and is then easily recessed into        the wall with the same hand. The hinge and pocket for cover and        closing systems are more thoroughly described under Detailed        Description.    -   3. Child Safety. The lack of market penetration by related art        that is primarily designed for child safety reflects the        inconvenience of use by other than children, the manufacturing        cost to construct the units, and in some cases, difficult and        time consuming installation. Conversely, the camouflage nature        of the invented item reduces interest of children and the        closing mechanisms can provide child safety without impeding use        by others or adding cost.    -   4. Energy Savings. According to the U.S. Department of Energy's        ‘Energy Savers Tips on Saving Energy and Money at Home’, two        percent of air escapes through electrical outlets/switches. This        occurs due to the space between the drywall cut and the        electrical box and through the outlet sockets. The flange of the        invented device seals the area between the drywall and the        electrical box. The cover of the invented device creates a        barrier between the outlet sockets and the room. Together the        flange and cover virtually eliminate this type of energy loss        and do so whether none, one, or both outlets are in use.

Other objects and features of the present invention will become apparentfrom the following detailed description considered in conjunction withthe accompanying drawings. It is to be understood, however, that thedrawings are designed solely for purposes of illustration and not as adefinition of the limits of the invention. It should be furtherunderstood that the drawings are not necessarily drawn to scale andthat, unless otherwise indicated, they are merely intended toconceptually illustrate the structures and procedures described herein.

BRIEF DESCRIPTION OF DRAWINGS

FIG. 1 is a front view showing a flange and cover of the presentinvention.

FIG. 2 is a side view showing an electrical box, flange and cover of thepresent invention.

FIG. 3 is a front view showing an electrical box of the presentinvention.

FIG. 4 is a front view showing an electrical box of the presentinvention.

FIG. 5 is front view showing an installed flange with open cover

FIG. 6 is a cutaway view of a flange of the present invention.

FIG. 7 is a view showing a closure mechanism and a cover of the presentinvention in a closed position.

FIG. 8 is a view showing an electrical box and a cover of the presentinvention at a midpoint between fully open and fully closed.

FIG. 9 is a view showing a cover of the present invention in an openposition.

FIG. 10 is a view showing an integrated hinge and cover of the presentinvention.

FIG. 11 is a front view showing an electrical box of the presentinvention.

FIG. 12 is a cutaway side view of an electrical box and track of thepresent invention.

FIG. 13 is a view showing a cover of the present invention.

FIG. 14 is a back view showing a cover of the present invention.

FIG. 15 is a view showing a cover of the present invention.

FIG. 16 is a view of a split side-by-side cover of the presentinvention.

FIG. 17 is a view showing a cover of the present invention.

FIG. 18 is a view showing a split over/under cover of the presentinvention.

FIG. 19 is a view showing a closure mechanism of the present invention.

FIG. 20 is a view showing a single cover

FIG. 21 is a view showing cover attachment points of the presentinvention.

FIG. 22 is a view showing cover hinge nodules

FIG. 23 is a view showing a hollow receptor of the present invention.

FIG. 24 is a view showing a receptor affixed to a flange and abutting acover of the present invention.

FIG. 25 is a view through a cover showing a receptor mount of thepresent invention.

FIG. 26 is a view showing a detent closure mechanism of the presentinvention.

FIGS. 27 and 28 are views showing an electrical box of the presentinvention.

FIG. 29 is a schematic showing a front view, side view and a rear viewof an electrical box of the present invention.

FIGS. 30 and 31 are views showing a flange of the present invention.

FIG. 32 is a schematic showing a front view, side views and a rear viewof a flange of the present invention.

FIG. 33 is a view showing a door of the present invention.

FIG. 34 is a schematic showing side views and a rear view of a door ofthe present invention.

DETAILED DESCRIPTION OF THE INVENTION

Embodiment modes of the present invention are explained below withrespect to the drawings. However, implementation of the presentinvention can be achieved in various different modes and withmodifications readily understood by those of ordinary skill in the art.Therefore, the present invention should not be construed to be limitedto specific embodiments of the present invention, including universalbox configurations or other integrated designs.

Embodiment 1

FIGS. 1 and 2 show the fully assembled unit, front and side view,installed with cover closed. The flange 1 surrounds and integrates theunit into the surrounding drywall 2. Cover 3 is closed with only theoutline 4 of the intersection of the flange and cover being visible. Theelectrical box 5 shown in FIG. 2, which is an integral component of thepresent invention, is obscured in FIG. 1 and the electrical outlet isobscured in FIGS. 1 and 2.

FIG. 3 shows the electrical box 5 having a height of 4.25″. The singlecover is retracted into the open box and only the leading edge 6 of thecover is exposed.

Top mounting plates 7 and 9 and bottom mounting plates 8 and 10 includeelectric outlet stabilizing tabs 11. On standard electrical boxes, thestabilizing tabs of the outlet rest on the outside edge of the box andextend beyond the top and bottom of the box.

According to one example of this embodiment, top mounting plate 7 andbottom mounting plate 8 may be formed, for example, recessed 1.75″ inelectrical box 5 to allow outlet 12 to be installed such that the faceof outlet 12 is recessed approximately 1.5″ from the front edge ofelectrical box 5.

According another example of this embodiment, top mounting plate 9 andbottom mounting plate 10 may be formed, for example, recessed ¼ ″inelectrical box 5 to allow outlet 12 to be installed such that the faceof outlet 12 is recessed approximately ⅙″ from the front edge ofelectrical box 5. Furthermore, electrical box 5 is formed having a widthsufficient to accommodate side by side outlets.

The dual mounting configuration of electrical box 5 allows outlet 12 tobe mounted in electrical box 5 over top mounting plate 7 and bottommounting plate 8 in order to be fully recessed, or over top mountingplate 9 and bottom mounting plate 10 in order to be slightly recessedand is interchangeable during initial home or office installation, oreven after initial installation.

By recessing outlet 12 inside the electrical box such that face ofoutlet 12 is recessed in accordance with this first embodiment, singlevertical cover when closed, will align flush with flange 1, which isflush with the wall on which electrical box 5 is installed and separatedonly by the thickness of the material from which flange 1 isconstructed. For the purpose of simplicity, all electrical boxessubsequently shown in this application are “single gang boxes” with onlyone set of mounting brackets.

FIG. 4 shows a front view of electrical box 5 without the outlet 12installed. The invention's second interior wall 13 attaches to the backwall of the electrical box 5 and continues toward the front edge of theelectrical box to the approximate depth of the bottom of the electricaloutlet when installed. This creates a channel into which the cover inembodiments 2 and 3 may recede into the box without interference byelectrical wire entering and/or exiting the electrical box. It alsoserves to separate the electrical connections from the flange opening,in accordance with Underwriters Laboratories safety specifications.Interior wall 13 would be included on any one or all four walls of theelectrical box, depending on the intended cover configuration. Theproximity of each interior wall 13 to the knockout tabs 14 for entry andexit of electrical wires into and out of the electrical box is shown.Guide tabs 5A are recessed from the leading edge of the electrical boxby a depth determined by the thickness of the drywall. It extends forapproximately 1.5″ perpendicular to the box, which is the approximatewidth of a 2×4 wooden stud. This provides for more consistent mountingof the box on a wooden stud than do the small notches on standard boxeswhich can be affected by the rounding of the corners of many 2×4s. Thedepth of the box in relation to the drywall is significantly more acutein this integrated design than with standard boxes and covers.Consistent mounting of the box in relation to the drywall is required inorder for the cover, when closed, to align flush with the flange whichis almost flush with the drywall, in keeping with the objective of theintegrated design, to obscure the outlet. Guide tabs 5A may beincorporated into each of Embodiments 1-4.

FIG. 5 shows the flange 1 to be used with the electrical box (notshown). Outlet 12 is in either mounting position 7/8 or 9/10 aspreviously outlined in FIG. 3.

The flange 1 rests flush on the drywall 2 protruding from the wall onlyby the width of the material from which it is constructed. The flange 1crosses the plane defined by the front of the electrical box (not shown)and immediately recesses into the electrical box at point 15 to a depththat is relative to the positioning of the outlet, 7/8 or 8/10 asindicated in FIG. 3. The flange 1 continues from both ends toward thecenter of the electrical box and is attached at the center screw 16 ofoutlet 12. In this manner, the flange protects the electrical wires andscrews on each side of the receptacle. The connection mechanism of theflange at the center screw 16 in either outlet position 7/8 or 9/10 isobscured when the cover is closed. The flange is therefore onecontinuous unit, except that the portion of the flange on the hinge sideof the electrical box stops as it crosses the plane of the electricalbox (not shown) at position 17, providing a channel for the cover inembodiments 2 and 3. Only the leading edge 6 of the open cover isexposed. When the cover is closed, the flange 1 at position 17 abuts andis flush with the trailing edge of the cover (not shown). FIG. 5 shows aflange configuration for a single cover, hinged on the left side ofelectrical box. However the cover and flange could be configuredsimilarly for hinging at the right, bottom, or top of electrical box, orany combination. Ground Fault Interrupter (“GFI” plugs) are configuredin the same manner except that the attachment points of the flange wouldbe at the top and bottom of the stabilizer mounts on the GFI plug 7/8,9/10 respectively, as shown on FIG. 3, because center screws are notincorporated into GFI outlets.

FIG. 6 shows a cutaway view of the flange 1, extending approximately ½inch over the drywall 2 cutout for the electrical box 5, on all foursides. The flange 1 enters the electrical box 5 on one to three walls ofthe electrical box depending on cover configuration. It would not extendinto the electrical box on the hinge side(s) of the electrical box, asshown in FIG. 5. On all sides, the flange 1 extends toward the outlet12, protecting the electric wiring.

FIG. 7 shows the first embodiment of the closure mechanism of theelectrical box 5. The electrical box is viewed from the bottom, withcover 3 in the closed position. The hinge 18 and cover 3 are formed asone molded or injected piece and are attached to electrical box 5 at 19and on the opposing side of electrical box 5. Note that the hinge can beattached to the interior or the exterior of the electrical box. The wirespring 20, is attached to hinge 18 at 21 and to electrical box 5 at 22.The expanded view of wire spring 20A shows its shape, which includes aminimal offset 20B and opposing 180 degree bends at 20C and 20D. Thisspring holds the cover closed when cover is closed and holds the coveropen when cover is open and it prevents cover from being left partiallyopen where it could be damaged by people or animals walking by theoutlet. The hinge and spring act as a counterweight, allowing the coverto be opened by pressing the cover 3 at 23, eliminating the need for ahandle or finger hole to open cover, supporting the purpose of thedesign which is to provide the appearance of an uninterrupted wall andobscuring the outlet. The electrical box 5 is angled at 24 to allow thecover to rotate down as further shown in FIGS. 8 and 9.

FIG. 8 shows the electrical box 5, viewed from the bottom with cover 3at the midpoint between opened and closed. The tab 25, extends from theleading edge 6 of cover 3, allowing cover, when open and recessed, to belifted, and it is obscured when cover is closed, further supporting theintention of the design to provide the appearance of an uninterruptedwall.

FIG. 9 shows the cover 3 in the fully open position. In this position,the hinge 18 is attached to the outside of electrical box 5 at 19 andthe cover rests outside the electrical box 5. If the hinge 18 isattached inside of the electrical box 5 at 19, the cover rests insidethe electrical box 5. Whether the hinge is mounted outside or insideelectrical box 5, only leading edge 6 is exposed when cover is open, asalso shown at 6 of FIG. 5. The box is angled at 24, as also shown inFIG. 7.

FIG. 10 shows the construction of integrated hinge and cover such thatthe hinge attached to an electrical box at connection point 19, anglesapproximately 90% at 25, then angles approximately 90% at 26.

Embodiment 2

FIG. 11 shows an electrical box according to a second embodiment of thepresent invention. The electrical box 5 in Embodiment 2 is substantiallysimilar to the electrical box in Embodiment 1; however, the closuremechanism differs. The closure mechanism in Embodiment 2 is formed asdual tracks 27 and 28 built into the electrical box, in which asectional door, attached to a roller, shall be inserted, much like avertically operated garage door and track. This door (or cover) retractsinto the electrical box, which is designed to accept the door due to thebox width, internal hinge tracks, and interior box wall (not shown) thatprevents interference from electrical wires inside the box, each morefully described under FIGS. 4. When combined with the coverconfiguration shown in FIG. 13, the electrical outlet is obscured whennot in use. Tracks 29 and 30 would support a horizontal (close across)closure utilizing the closures shown in FIG. 15 or FIG. 16. Screw holes31 and 32 for outlet attachment to electrical box 5 would be attached tobox 5 behind tracks 29 and 30 so not to interfere with cover movement.

When tracks 29 and 30 are used and when combined with outlet positioning7/8 in FIG. 2, and when combined with a split side-by-side cover asshown in FIG. 17, the connection point between the electrical wire andthe electrical outlet is obscured, even when an electrical plug isengaged, providing the visual effect of electrical wires entering awall.

Tracks 27 and 28, when utilized in conjunction with cover shown in FIG.18 and with outlet position 7/8 or 9/10 in FIG. 3, a single outletconnector may be covered while the other outlet connector is in use.

In each configuration, covers are stored in the electrical box when theoutlet is in use, obscuring them from view.

FIG. 12 shows a cutaway side view of electrical box 5 and track 28supporting a vertical closure. An opening 33 in track 28 allows for theinsertion of the rollers attached to the cover. A similarly styledinsertion point would be utilized for tracks 27, 29 and 30 shown in FIG.11.

FIG. 13 shows a single vertically closing cover 34 constructed invarious sections 35 and attached to rollers 36 that would mount into thehinge tracks 27 and 28 in FIG. 11.

FIG. 14 shows the back of cover 34 shown in FIG. 13 with hinges 37 ateach section 35, holding the sections together allowing the cover tofollow a curved track 28 of FIG. 12,

FIGS. 15-18 show various cover configurations that would integrate withvarious cover track configurations in the second embodiment of theelectrical box.

FIG. 15 shows a single cover that would mount into the hinge tracks 29and 30 shown in FIG. 11. The door, built in panels or sections 35, allowit to follow in the curved tracks 29 and 30 in FIG. 11. Each cover inFIGS. 15-18 incorporate the same sectional design, though not shown.

FIG. 16 shows a split side-by-side cover that would mount into the hingetracks 29 and 30 shown in FIG. 11. This configuration would beincorporated with recessed outlet positioning 7/8 in FIG. 3, obscuringthe electrical plugs and outlet, even when in use.

FIG. 17 illustrates a close up view of the cover illustrated in FIG. 16,incorporating cutouts 38 for electrical cords engaged in the outlet.Spring-loaded sliding plates on the back side of each cover wouldobscure cutouts 38 when the outlet is not in use.

FIG. 18 illustrates a split over/under cover for use in hinge tracks 27and 28 in FIG. 11, allowing one outlet to be covered while the other isin use.

Embodiment 3

FIG. 19 shows Embodiment 3 of the closure mechanism incorporated intothe electrical box 5. The electrical box 5 in Embodiment 3 issubstantially similar to the electrical box in Embodiments 1 and 2;however, the closure mechanism differs. The top mounted hinge tracks 39and bottom mounted hinge tracks 40 are built into the electrical box 5,can receive cover hinges shown in FIGS. 20 and 21, and are formed ononly one side of the electrical box 5, rather than three sides inEmbodiment 2.

Tracks 41/42, when combined with 39/40, can receive split side-by-sidecovers. Tracks 43/44 provide a single vertical (close down) coverconfiguration and when utilized with tracks 45/46 and a split verticalcover, a single outlet may be obscured while other outlet is in use.

The invented electrical box could accommodate all or any one of theabove configurations.

FIGS. 20 and 21 show that Embodiment 3 is configured to integrate solid(non-sectional) covers attaching only at cover hinge nodules 47 and 48on the trailing edge 49 of the cover 3. The attachment points could bepositioned at the bottom or top, or the left or right of all sides ofcover 3, depending on the intended track configuration of electrical boxas described in FIG. 19. The leading edge 6 of cover 3 is unattached tohinge tracks and therefore requires a separate closing mechanismincluding magnets or detents to hold it in place when closed.Conversely, Embodiment 2 includes a sectional cover attaching at fourpoints to a curved track and therefore does not need a separate closuremechanism to hold it in place when closed.

FIG. 22 illustrates the shape of the cover hinge nodules 47 and 48. Asshown in 50A and 50B, the hinge is positioned on the inside of the coversuch that the profile of the hinge would not exceed that of the coverand would not protrude from the drywall or electrical box when cover isclosed.

FIG. 23 shows hollow receptor 51 that will accept a flat magnet mount ora touch latch magnet mount.

FIG. 24 shows the position of the receptor 51 affixed to flange 1 andabutting cover 3.

FIG. 25 shows a see-through view through cover 3 to receptor 51 asdescribed in FIGS. 23 and 24 positioned at either 52 or 53, depending onthe cover configuration.

FIG. 26 shows a detent closing mechanism 54 built into cover 3 with anopposing detent 55 in flange 1.

Embodiment 4

FIGS. 27-34 show a further embodiment of the present invention. In FIGS.27 and 28, electrical box 60 is shown, which has been provided withmounting tabs 61 to allow the box to be installed or attached to astructure with minimized installation error (e.g., ensuring propermounting depth). Furthermore, electrical box 60 is optimally shapedhaving dimensions to comply with code specifications requiring specificcubic volume, while concurrently limiting or minimizing the size of anydrywall cut required to install the electrical box 60.

An electrical outlet may be mounted to screw holes tabs 62 such that theoutlet is attached within electrical box 60. Specifically, screw holetabs 62 are provided at a depth allowing an electrical outlet mountedsuch that an attached flange 65 (shown in FIGS. 30 and 31) intersectswith electrical box 60 in a manner that avoids displacement of theflange 65 by such screws. For example, when an electrical outlet ismounted to screw hole tabs 62 with dome screws, the depth of screw holetabs 62 is sufficient to allow intersection of the flange 65 and theelectrical box 60 having a finished fit and avoids rocking of the flange65.

Electrical box 60 also includes internal wall 63, provided to separatewires connected to an outlet terminal from interfering with the movementof door 65 (shown in FIG. 33). When an outlet is installed withinelectrical box 60, wiring connected to the outlet is constrained to aninner portion of internal wall 63. Accordingly, even when door 70 orflange 65 (shown in FIGS. 30 and 31) is removed from electrical box 60,a connected wiring would remain partitioned by internal wall 63, toavoid unintended contact with the connected wiring. For example, if achild were to remove either door 70 or flange 65 from electrical box 60,access to electrical connections would still be impeded by internal wall63, according to this embodiment of the present invention.

With an electrical outlet attached to electrical box 60 at screw holetabs 62, flange 65 is provided such that it can be attached theelectrical outlet through screw hole 66. Door 70 can be attached toflange 65 by coupling hinge nodule 72 of door 70 to hinge receptor 68 offlange 65. When attached to flange 65, door 70 can traverse door opening67, such that door 70 can be closed flush with flange 65 oralternatively retracted inside electrical box 60. Hence, both the flange65 and door 70 are adapted to, yet removable from, electrical box 60. Assuch, the attachment mechanism of each part is configured to ensure aconsistent relationship and finished fit, while also allowing easymaintenance or replacement of the individual parts, such as the flange65 and the door 70.

Furthermore, by coupling the flange 65 with the door 70 at hingeportions 69 and 71, respectively, instead of edge portions, theinterface of flange 65 and door 70 can be hidden within electrical box60 by the bevel and reverse bevel of flange 65 and door 70, so as tocreate a satisfying aesthetic appearance. In addition, the hingemechanism including hinge portions 69 and 71 is provided having a shapethat allows the hinge to rotate, yet intersect the flange at arelatively flat angle (that is, less than 90°. Accordingly, door 70 maybe opened and closed with minimal required clearance, such that anelectrical outlet installed within electrical box 60 may be safely andeasily accessed, for example, behind furniture and other objects thatare situated in front of the outlet, which embodiments 2 and 3 do notprovide.

A flange 65 according to this embodiment can be manufactured using“Finite Element Analysis” manufacturing techniques, which are known inthe art and not described herein, to allow production of flange 65 withextremely thin, yet durable, material. A flange 65 produced in thismanner will allow extreme tapering of the flange's intersection withsurrounding drywall (or other adjoining surface).

Furthermore, a flange 65 and/or a door 70 of this embodiment can beprovided with opening/closing mechanisms including, for example, akinematic push/pull opening mechanism or a spring assisted door, thatfacilitate the operation of the door. Such opening/closing mechanismallows the user access by pushing lightly on the hinge side of the doorand have it open fully, allowing one-handed access by a user with anelectrical chord in hand, which embodiments 2 and 3 do not provide. Italso can enhance the safety features of the present invention, forexample, by mechanically shutting a door 70 that is only partiallyopened and reducing the risk that door 70 is inadvertently opened orleft open.

This embodiment of the present invention therefore achieves additionalsafety and aesthetic advantages by integrating an electrical box, flangeand door, such that the door is easily accepted into the flange andinside the electrical box with minimal interference from within theelectrical box or by the attachment mechanism and minimal clearancerequired outside of the electrical box.

Each embodiment of the present invention described above can be furtheradapted and implemented in a variety of different combinations withmodifications readily understood by those of ordinary skill in the art.Therefore, the scope of the present invention is intended to becomprehended in accordance with the general knowledge of the art andshould not be construed to be limited solely to the above describedembodiments.

1. An electrical box device comprising: an electrical box having aninternal wall; a flange configured to be attachable to said electricalbox, wherein said flange further comprises a hinge mechanism thatintersects the flange at an angle less than 90°; and a door configuredto be attachable to said flange by said hinge mechanism.